When Lifting Systems in Northampton set out to improve their paint operations, they were facing rising costs, excessive waste, and an increasingly difficult working environment for their painters. Within months of partnering with Ultrimax, they achieved a 50% reduction in paint consumption, dramatically cleaner workspaces, and finish quality improvements that customers immediately noticed.
About Lifting Systems
Established in 1994, Lifting Systems has been at the forefront of providing safety-certified lifting equipment and cutting-edge gantry crane solutions to industries across the United Kingdom. With over 80 years of collective team experience, they specialise in designing, manufacturing and testing overhead factory cranes and gantry structures to the highest safety standards.
Lifting System Paint Operations
The dedicated paint bay is critical to Lifting Systems' operations, applying industrial-grade coatings that enhance both durability and safety of their lifting equipment. Paint operations involve:
- Large-scale gantry crane components and overhead crane structures
- Bespoke fabricated lifting equipment requiring professional finishes
- Industrial coating applications that must withstand demanding environments
- High-volume paint usage across multiple workstations
For Lifting Systems, paint quality isn't just about appearance - it's about protection, safety compliance, and customer satisfaction on equipment that serves critical industrial applications nationwide.
The Challenge
Like many customers using traditional paint application methods, Lifting Systems recognised several areas where their paint operations could be improved to better serve their environment, and their team:
- Using 80 litres of paint for jobs that should have required far less
- Significant material waste eating into profit margins
- Rising paint costs making operations increasingly expensive
Heavy overspray was creating workspace floors that required constant cleaning, while paint particles contaminated the air and surfaces, contributing to a less-than-ideal working environment for their painters. The team also sought to improve their finish quality and consistency to meet evolving customer expectations for premium coating appearance. Additionally, the escalating costs of thinners, solvents, and waste disposal were mounting. The situation presented a clear opportunity: by modernising their paint system, Lifting Systems could reduce costs, minimise waste, and create a healthier, more efficient working environment.
The Ultrimax Solution
Ultrimax approached the challenge with a comprehensive two-part solution designed to address both the application process and waste management.
Advanced Electrostatic Spray Technology
At the heart of the transformation was the Wagner Leopard 35-70 Air Assisted Airless Sprayer paired with a Wagner GM5000 EAC electrostatic gun. This sophisticated system uses electrostatic charging to ensure paint particles are attracted directly to the metal surfaces, virtually eliminating overspray and maximising transfer efficiency, click here to view more information about electrostatic spraying.
Sustainable Solvent Recycling
Complementing the spray system, Ultrimax installed a 25-litre capacity Unic solvent recycler that transforms contaminated solvents into fresh, reusable thinners. This closed-loop approach not only reduces environmental impact but also delivers substantial ongoing cost savings by eliminating the need to constantly purchase new thinners and dispose of hazardous waste.
The Results:
- 50% reduction in paint consumption - jobs previously requiring 80 litres now completed with just 40 litres
- Elimination of constant thinner purchases through solvent recycling
- Reduced waste disposal costs
- Improved profit margins on every painted component
Daniel Hoare, Account Manager at Ultrimax, reflects on the project: "Working with Lifting Systems has been incredibly rewarding. To see them achieve a 50% reduction in paint usage while simultaneously improving finish quality and creating a healthier workspace for their team - that's exactly what we aim to deliver."
The painters at Lifting Systems immediately noticed the difference. Floors that previously required constant cleaning now stay remarkably clean thanks to minimal overspray. Air quality improved significantly with fewer paint particles contaminating the workspace. As one painter put it: "Can't believe how good electrostatic is and as for the paint it is amazing, a really good finish and especially easy to use."
The partnership between Lifting Systems and Ultrimax demonstrates that with the right technology and expertise, manufacturers can simultaneously reduce costs, improve quality, and create better working environments.
Are rising paint costs and excessive waste impacting your operations? Contact Ultrimax today to discover how electrostatic spray technology and solvent recycling could transform your paint shop just as it did for Lifting Systems.